2011-2014 SYM MAXSYM 400I Scooter Service & Repair Manual

MAXSYM 400i / 400i ABS / 600i ABS SERVICE MANUAL 201404 FOREWORD HOW TO USE THIS MANUAL CONTENTS MECHANISM ILLUSTRATION

Foreword This service manual contains the technical data of each component inspection and repair for the Sanyang MAXSYM 400i / 400i ABS / 600i ABS scooter. The manual is shown with illustrations and focused on “Service Procedures”, “Operation Key Points”, and “Inspection Adjustment” so that provides technician with service guidelines. If the style and construction of the motorcycle, MAXSYM 400i / 400i ABS / 600i ABS, are different from that of the photos, pictures shown in this manual, the actual vehicle shall prevail. Specifications are subject to change without notice. Service Department Sanyang Industry Co., LTD. Homepage Contents

How to Use This Manual This service manual describes basic information of different system parts and system inspection & service for Sanyang MAXSYM 400i scooter. In addition, please refer to the manual contents in detailed for the model you serviced in inspection and adjustment. The first chapter covers general information and trouble diagnosis. The second chapter covers service maintenance information. Th third to the twelfth chapter covers the engine and driving systems. The thirteenth to the sixteenth is contained the parts set of assembly body. The seventeenth chapter is electrical equipment. The eighteenth chapter is wiring diagram. Please see index of content for quick having the special parts and system information. There are 4 buttons, “Foreword”, “Contents”, “How to Use This Manual” and “Mechanism Illustration” in the PDF version, and can be access to these items by clicking on the buttons. If user wants to look for the content of each chapter, selecting the words of each chapter on the contents can reach to each chapter. There are two buttons, “Homepage and contents, on the top line of first page of the each chapter. Thus, if the user needs to check other chapters, he can click the top buttons to back the homepage or contents. The content of each chapter can be selected too. Therefore, when needs to checking the content inside of the chapter, click the content words of the chapter so that can back to the initial section of the content. In addition, there is a “To this Chapter Contents” button at the second page of each content so that clicking the button can back to the contents of this chapter. Homepage Contents

Contents Page Content Index 1-1 ~ 1-18 General Information 1 2-1 ~ 2-16 Maintenance Information 2 3-1 ~ 3-6 Lubrication System 3 4-1 ~ 4-58 Fuel Injection System 4 5-1 ~ 5-4 Engine Removal 5 6-1 ~ 6-16 Cylinder Head / Valve 6 7-1 ~ 7-8 Cylinder / Piston 7 8-1 ~ 8-14 V-Belt Drive System 8 9-1 ~ 9-8 Final Drive Mechanism 9 10-1 ~ 10-4 AC Generator / Starting Clutch 10 11-1 ~ 11-8 Crankshaft / Crankcase 11 12-1 ~ 12-12 Cooling System 12 13-1 ~ 13-16 Body Cover 13 14-1 ~ 14-12 Brake System 14 15-1 ~ 15-11 Steering / Front Wheel / Front Cushion 15 16-1 ~ 16-6 Muffler / Rear Wheel / Rear Cushion 16 17-1 ~ 17-22 Electrical System 17 18-1 ~ 18-2 Wiring Diagram 18 Homepage Contents

Mechanism Illustration Front winker Luggage box Start / engine stop switch Dimmer / winker / horn seat open / pass switch Muffler Reserve tank cap Coolant filler cap Main switch Fuel tank / fuel pump Side stand Back mirror Headlight Front brake lever Rear brake lever Home page Contents Main stand Air cleaner Taillight / rear winker Engine number

1. General Information 1-1 Symbols and Marks ······················· 1-1 General Safety ······························ 1-2 Before Servicing ··························· 1-3 Specifications ······························· 1-9 Torque Values ······························· 1-10 Troubleshooting ···························· 1-12 Lubrication Points ························· 1-16 Symbols and Marks Symbols and marks are used in this manual to indicate what and where the special service is needed. If supplemental information is needed for these symbols and marks, explanations will be added in the text instead of using the symbols or marks. Warning Means that serious injury or loss of life may happen if procedures are not correctly followed. Caution Means that equipment damages may result if procedures are not followed. Engine oil Limits to use SAE 10W-30 API SG class oil. Warranty will not cover the damage that caused by not apply with the limited engine oil. (Recommended oil: KING MATE G-3 oil) Grease King Mate G-3 is recommended. Locking sealant Apply sealant; medium strength sealant should be used unless otherwise specified. Oil seal Apply with lubricant.。 Renew Replace with a new part before installation. Brake fluid Use recommended brake fluid DOT3 or WELLRUN brake fluid. Special tools Special tools Correct Meaning correct installation. Wrong Meaning wrong installation. Indication Indication of components. Directions Indicates position and operation directions Components assembly directions each other. Indicates where the bolt installation direction, --- means that bolt cross through the component (invisibility). Homepage Contents 1

1. General Information 1-2 General Safety Carbon Monoxide Before you start the engine, make sure the place is well ventilated. Never start the engine in an unventilated place. If you have to start the engine in an unventilated place, an exhaust fume extractor is needed. Caution Exhaust fume contains toxic gas which may cause one to lose consciousness and even result in loss of life. Gasoline Gasoline is a low ignition point and explosive material. Work in a well-ventilated place, no flame or spark should be allowed in the work place or where gasoline is being stored. Caution Gasoline is highly flammable, and may explode under some conditions, keep it away from the children. Used Engine Oil Caution Prolonged contact with the used engine oil (or transmission oil) may cause skin cancer although it might not be verified yet. We recommend that you wash your hands with soap right after contacting. Keep the used oil beyond reach of the children. Hot Components Caution Components of the engine and exhaust system can be extremely hot after engine running. They remain very hot even after the engine has been stopped for a period of time. Before performing service work on these parts, wear the heat insulation gloves or wait until the temperature drops. Battery Caution ‧ Battery emits explosive gases; flame is strictly prohibited. Keep the place well ventilated when the battery is being charged. ‧ Battery contains sulfuric acid (electrolyte) which can cause serious burns, be careful not to spill it on your skin or eyes. If you get battery fluid on your skin, flush it off with water immediately. If you get battery fluid in your eyes, flush it off immediately with water and go to hospital to see an ophthalmologist doctor. ‧ If you swallow the battery fluid by mistake, drink a lot of water or milk, and take some laxative such as Epsom salts or vegetable oil and then go to see a doctor. ‧ Keep the battery and battery fluid beyond reach of the children. Brake Shoes Do not use compressed air or brush to clean the components of the brake system. Use a vacuum cleaner or the equivalent to avoid dust drifting in the air. Caution Inhaling brake shoes dust may cause disease or even cancer of the respiratory system. Brake Fluid Caution Brake fluid spilled on painted, plastic, or rubber parts may cause damage to the parts. Place a clean towel on the top of the parts for protection when servicing the brake system. Keep the brake fluid beyond reach of the children. To this chapter contents

1. General Information 1-3 Before Servicing  Always use SANYANG genuine parts and recommended oil. Using improper parts may cause damage to or destruction of the vehicle.  Special tools are designed for removal and installation of component parts without damaging them. Using wrong tools may result in parts damage.  When servicing this vehicle, use only metric tools. Metric bolts, nuts, and screws are not interchangeable with the Britain system, using wrong tools and fasteners may damage this vehicle.  Clean the outside of the parts or the cover before removing it from the vehicle. Otherwise, dirt and deposit accumulated on the part's surface may fall into the engine, chassis, or brake system to cause damage.  Wash and clean parts with high flash point solvent, and then blow dry with compressed air. Pay special attention to O-rings or oil seals because most of the cleaning agents have bad effect on them.  Never bend or twist control cables to avoid unsmooth control and premature worn out.  Rubber parts may become deteriorated when old, and be damaged by solvent and oil easily. Check these parts before installation to make sure that they are in good condition, replace if necessary.  When loosening a component which has different sized fasteners, operate with a diagonal pattern and work from inside out. Loosen the small fasteners first. If the bigger ones are loosen first, small fasteners may receive too much stress.  Store complex components such as transmission parts in the proper assemble order and tie them together with a wire for ease of installation later.  Note the reassemble position of the important components before disassembling them to ensure they will be reassembled in correct dimensions (depth, distance or position).  Components not to be reused should be replaced when disassembled including gaskets metal seal rings, O-rings, oil seals, snap rings, and split pins. To this chapter contents

1. General Information 1-4  The length of bolts and screws for assemblies, cover plates or boxes is different from one another, be sure they are correctly installed. In case of confusion, Insert the bolt into the hole to compare its length with other bolts, if its length out side the hole is the same with other bolts, it is a correct bolt. Bolts for the same assembly should have the same length.  Tighten assemblies with different dimension fasteners as follows: Tighten all the fasteners with fingers, then tighten the big ones with special tool first diagonally from inside toward outside, important components should be tightened 2 to 3 times with appropriate increments to avoid warp unless otherwise indicated. Bolts and fasteners should be kept clean and dry. Do not apply oil to the threads.  When oil seal is installed, fill the groove with grease, install the oil seal with the name of the manufacturer facing outside, and check the shaft on which the oil seal is to be installed for smoothness and for burrs that may damage the oil seal.  Remove residues of the old gasket or sealant before reinstallation, grind with a grindstone if the contact surface has any damage.  The ends of rubber hoses (for fuel, vacuum, or coolant) should be pushed as far as they can go to their connections so that there is enough room below the enlarged ends for tightening the clamps.  Rubber and plastic boots should be properly reinstalled to the original correct positions as designed.  The tool should be pressed against two (inner and outer) bearing races when removing a ball bearing. Damage may result if the tool is pressed against only one race (either inner race or outer race). In this case, the bearing should be replaced. To avoid damaging the bearing, use equal force on both races. Both of these examples can result in bearing damage. Manufacturer's name Groove Clamp Connector Boots To this chapter contents

1. General Information 1-5  Lubricate the rotation face with specified lubricant on the lubrication points before assembling.  Check if positions and operation for installed parts is in correct and properly.  Make sure service safety each other when conducting by two persons.  Note that do not let parts fall down.  Before battery removal operation, it has to remove the battery negative (-) cable firstly. Notre tools like open-end wrench do not contact with body to prevent from circuit short and create spark.  After service completed, make sure all connection points is secured. Battery positive (+) cable should be connected firstly.  And the two posts of battery have to be greased after connected the cables.  Make sure that the battery post caps are located in properly after the battery posts had been serviced.  If fuse burned, it has to find out the cause and solved it. And then replace with specified capacity fuse. Capacity verification To this chapter contents

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2011-2014 SYM MAXSYM 400I Scooter Service & Repair Manual

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